Flat-shippable cornice or valance system

ABSTRACT

A simplified and light-weight cornice or valance system that can be manufactured along with a window covering in colors and patterns to match, shipped flat, and easily installed with the window covering is disclosed. The cornice or valance system may include a single-piece core with a foldable region near each end, the foldable regions defining a central non-foldable region and an end return non-foldable region at each end of the central non-foldable region; and an angle bracket for coupling to each side of a selected foldable region to retain a desired angle between the central non-foldable region and the respective end return non-foldable region.

This application claims priority to U.S. Provisional Patent Application No. 61/791,640, filed Mar. 15, 2013, and hereby incorporated by reference.

BACKGROUND

1. Technical Field

The disclosure relates generally to window treatments, and more particularly, to a cornice or valance system that can be shipped flat and is used to cover the upper portion (and hardware) of a window treatment such as a shade or drapery. The cornice or valance system may have a pre-formed pattern thereon or have fabric covering having a pre-determined pattern.

2. Background Art

Many windows are fitted with light-control treatments such as drapes, roller shades or blinds. All of these window treatments have some form of hardware at the top to mount the window treatment and enable its actuation (movement or deployment for variable coverage and light control). Such hardware systems are often unsightly and are therefore covered with cornice or valance systems. It is a desire of many users of such window treatments to have a matching pattern or color on the window treatment and the cornice or valance. Such matching has heretofore most often been achieved in workroom environments where fabric is sewn and stapled to heavy wooden or metal constructions that then are mounted over the window and hardware by brackets independent of the window treatments, requiring further carpentry and holes in the walls or window frame. This difficulty of fabrication and installation (with the associated expense) has limited the use of such fabric-covered (or upholstered) valances and cornices, despite their aesthetic appeal.

BRIEF SUMMARY

A simplified and light-weight, fabric-covered or patterned cornice or valance system that can be manufactured along with a window covering in colors and patterns to match, shipped flat, and easily installed with the window covering is disclosed.

A first aspect of the disclosure provides a cornice or valance system for use with or over a window treatment, the system comprising: a single-piece core with a foldable region near each end, the foldable regions defining a central non-foldable region and an end return non-foldable region at each end of the central non-foldable region; a slot, associated with the single-piece core, to each side of each foldable region; and an angle bracket for inserting into the slots to each side of a selected foldable region to retain a desired angle between the central non-foldable region and the respective end return non-foldable region.

A second aspect of the disclosure provides a cornice or valance system for use with or over a window treatment, the system comprising: a single-piece core with a pair of foldable regions near each end, the foldable regions defining a central region and two return regions; an assembly system having a first piece coupled to each return region and a second piece coupled to the central region, each piece including a first, coupling portion for coupling to the single-piece core and a slot portion; and an angle bracket for engaging adjacent slot portions of one of the return regions and the central region to retain a desired angle between the central region and the respective return region.

A third aspect of the disclosure provides a method of creating a cornice or valance system for use with or over a window treatment, the method comprising: forming a pair of foldable regions near each end of a single-piece core, the foldable regions defining a central region and two return regions, the single-piece core includes one of a pattern and a fabric covering having a pattern; coupling a first piece of an assembly system to each return region and coupling a second piece of an assembly system to the central region, each piece including a first, coupling portion for coupling to the single-piece core and a slot portion; and providing for later assembly at least one angle bracket for engaging adjacent slot portions of one of the return regions and the central region to retain a desired angle between the central region and the respective return region.

A fourth aspect of the disclosure includes a cornice or valance system for use with or over a window treatment, the system comprising: a single-piece core with a foldable region near each end, the foldable regions defining a central non-foldable region and an end return non-foldable region at each end of the central non-foldable region; and an angle bracket for coupling to each side of a selected foldable region to retain a desired angle between the central non-foldable region and the respective end return non-foldable region.

The illustrative aspects of the present disclosure are designed to solve the problems herein described and/or other problems not discussed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure, in which:

FIG. 1 shows a front side perspective view of one end of a cornice or valance system in a mounted position according to embodiments of the invention.

FIG. 2 shows a front side perspective view of a cornice or valance system in a flat shipping position according to embodiments of the invention.

FIG. 3 shows a rear perspective view of a single-piece core of the cornice or valance system at a foldable region thereof according to embodiments of the invention.

FIG. 4 shows a schematic rear view of the single-piece core of FIG. 3.

FIG. 5 shows a back side view of a cornice or valance system during assembly according to embodiments of the invention.

FIG. 6 shows a back side view of a cornice or valance system after assembly according to embodiments of the invention.

FIG. 7 shows a cross-sectional view of part of an assembly system for a cornice or valance system according to embodiments of the invention.

FIG. 8 shows a back side view of a cornice or valance system after assembly according to alternative embodiments of the invention.

FIG. 9 shows a front perspective view of a mounting bracket on a cornice or valance system according to embodiments of the invention.

FIGS. 10A-C show perspective views of a variety of mounting brackets for a cornice or valance system according to embodiments of the invention.

It is noted that the drawings of the disclosure are not to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. In the drawings, like numbering represents like elements between the drawings.

DETAILED DESCRIPTION

Embodiments of the present invention include a cornice or valance system 10 (FIGS. 1-2) that is simplified and light-weight compared to conventional systems. In addition, system 10 may be fabric-covered or patterned and can be manufactured along with a window covering in colors and patterns to match, shipped flat to reduce damage, and easily installed with the window covering. System 10 can be ordered to required dimensions. FIG. 1 shows cornice or valance system 10 in a mounted position, while FIG. 2 shows cornice or valance system 10 in a flat, shipping position. System 10 may be used with or over a window treatment 13 (FIG. 1). As used herein, ‘cornice or valance’ indicates an extent of material hung above or on a window to screen window treatment fittings. A cornice may be positioned near a ceiling and a valance is may not be so positioned.

Turning to FIGS. 3-4, cornice or valance system 10 includes a single-piece core 12 that may be made from a lightweight, substantially rigid, cellular or porous polymer sheet material 14. FIG. 3 shows a rear perspective view of single-piece core 12, and FIG. 4 shows a schematic rear view of single-piece core 12, each without any fabric covering. In one example, sheet material 12 may include an extruded polypropylene hollow-cored sheet material such as COROPLAST™, a product of the Jim Pattison Group, Vancouver, BC. However, any sheet material having outer skins (i.e., sheet-like planar faces or layers) and a less substantial inner structure such as a fluted polymer or corrugated polymer may be employed. In any event, a single-piece core 12 has a height appropriately selected for a particular window treatment, as known in the art, which may be user specified during ordering.

Single-piece core 12 also includes a foldable region (or band) 16 near each end. Foldable regions 16 define a central non-foldable region 18 and an end return non-foldable region 20 at each end of central non-foldable region 18. Central non-foldable region 18 has a length selected (e.g., by a user during ordering) to match that necessary for the particular window treatment, when end return non-foldable regions 20 are folded to form the elongated U-shape of the cornice or valance, as will be described in more detail herein. Foldable regions 16 may be formed in sheet material 12 by removing portions of sheet material 12 to provide more flexible regions 16. In the example shown in FIG. 3, foldable regions 16 are formed by removing through routing, milling or other mechanical means one planar face of a fluted polymer and substantially all of the intermediate material (leaving only one face) in two local transverse (to length) routed regions 16 (only one shown in FIG. 3); that is, removing the fluting up to the opposing planar face. Each flexible region 16 may have a width of about 1 inch (may possibly be in a range of 0.5-1.5 inches) at a separation substantially equal to the desired installed length of the cornice. (End return non-foldable regions 20 are also sized to order to accommodate the particular window treatment, i.e., substantially equal to the installed depth of the desired returns.) In this manner, a foldable region 16 is created that is weaker in strength and readily foldable compared to the remaining end return non-foldable regions 20. Foldable regions 16 may be formed in a variety of other fashions now known or later developed. For example, single-piece core 12 with flexible regions 16 therein could be extruded as a single, integral member.

Referring again to FIG. 1, single-piece core 12 may have a pattern thereon or be covered (wrapped) with a fabric (upholstery) 26 having a pattern thereon. As used herein, “pattern” may include any form of decoration including simply a color and/or a decorative design. In one embodiment, a pattern of fabric 26 matches a pattern of an associated window covering material 13 of the window treatment. In one embodiment, fabric 26 may be printed to order with a unique, buyer-specified pattern. In this fashion, cornice or valance system 10 can be highly customized. Fabric 26, to cover this rigid, single-piece core 12 is cut wide and longer than the core and then adhered to one face of the core, using for example adhesives of known type, such as pressure-sensitive double-sided tape with acrylic adhesive. As shown best in FIG. 5, fabric 26 is then folded over the edges and stapled (not shown) or taped to the back side of single-piece core 12 (inside fabric).

As shown in FIG. 5, a slot 40 is associated with single-piece core 12 to each side of each foldable region 16 (within folded corner). In one embodiment, slot 40 may be provided by an assembly system 50 attached to single-piece core 12. As shown, assembly system 50 may be attached to the back side of the fabric covered core 12. As shown in FIGS. 5 and 6 (left upper corner) and in cross-section in FIG. 7, assembly system 50 includes a coupling portion 56 for coupling to core 12, and a slot portion 58 for engagement by an angle bracket 60 (FIGS. 5 and 6), as will be described. Coupling portion 56 may have a substantially L-shaped section with a longer cornice portion 78 and a shorter coupling portion 80. Assembly system 50 can be provided in the form of an extrusion of appropriately stiff plastic or other material. Slot portion 58 in conjunction with coupling portion 56 creates slot 40 in which angle bracket 60 (FIGS. 5-6) can be affixed. As shown in FIGS. 5-6, coupling portion 56 may be coupled to core 12, e.g., via staples, adhesives, screws or other permanent fixing mechanism. Assembly system 50 includes two shorter pieces 64 (one shown in FIGS. 5-6, other at other end) mounted one each on end return non-foldable regions 20 (FIG. 1) and one longer piece 66 between foldable regions 16 (foldable region 16 is hidden by fabric 26 in FIGS. 5-6), mounted to central region 18. Coupling portion 56 of each piece 64, 66 is coupled to core 12 with slot 40 unobstructed and substantially aligned between pieces 64 and 66 such that slot 40 of each region align for receipt of angle bracket 60 when core 12 is folded into a cornice/valance shape. Although one embodiment of providing slot 40 has been illustrated and described, it is understood that a variety of other structures may be employed to associate the requisite slot(s) 40 with single-piece core 12, e.g., slots could be integrally formed with core 12 and/or otherwise attached to core 12.

Turning to the details of assembly of system 10, when shipped, single-piece core 12 lies flat, as shown in FIG. 4, to ease shipment and reduce damage. At installation, core 12 is folded such that end return non-foldable regions 20 are turned along foldable regions 16 to the positions shown in FIGS. 5-6, bringing slots 40 of the respective pieces 64, 66 of assembly system 50 into a desired angle, e.g., a substantially 90-degree orientation. As shown in FIGS. 5-6, an angle bracket (or angle key) 60 of, for example, steel or other inexpensive but rigid material, is provided to engage slot portion 58, i.e., fit snugly (by matching of thickness) into slot 40. That is, an angle bracket 60 is provided for inserting into slots 40 to each side of a selected foldable region 16 to retain a desired angle between the central non-foldable region 18 and the respective end return non-foldable regions 20, thus creating the U-shape of cornice or valance system 10. Angle brackets 60 may be simply pushed into place to retain the substantially 90 degree bends of end return non-foldable regions 20 of core 12 with central region 18—thereby becoming the end returns of cornice or valance system 10. Slot portions 58, as shown best in FIG. 7, may include snap ends 70 to retain angle bracket 60 therein. Angle brackets 60 may be angled other than at 90-degrees to allow the cornice to be at, or appear to be at the desired angle. For example, angle bracket 60 may be angled at 80-85 degrees (e.g., 83 degrees). A variety of angle brackets 60 may be provided with system 10. Also, while angle bracket 60 has been illustrated with holes in each length, e.g., for screws, they are not necessary in all cases.

Turning to FIG. 8, other retention mechanisms for an angle bracket 160 may also be employed, e.g., screws, adhesives, hook-n-loop fasteners, etc. FIG. 8 shows one other illustrative embodiment in which an assembly system 150 is attached to single-piece core 12. As shown, assembly system 150 may be attached to the back side of the fabric covered core 12. As shown, assembly system 150 includes a coupling portion 156 for coupling to core 12, and respective bracket attachment portions 158 (behind bracket 160) for engagement by an angle bracket 160. Coupling portion 156 may have a substantially L-shaped section with a longer cornice portion 178 and a shorter coupling portion 180. Assembly system 150 can be provided in the form of an extrusion of appropriately stiff plastic or other material. Bracket attachment portions 158 can be any structure or simply an area providing for affixation of angle bracket 160 using, for example, adhesive, screws (not shown), mating hook-n-loop fasteners on bracket 160 and portions 158, etc. Coupling portion 156 may couple to core 12, e.g., via staples, adhesives, screws or other permanent fixing mechanism. As in the previous embodiment, assembly system 150 includes two shorter pieces 164 (one shown in FIG. 8, other at other end) mounted one each on end return non-foldable regions 20 and one longer piece 166 between foldable regions 16 (foldable region 16 is hidden by fabric 26 in FIG. 8), mounted to central region 18. Coupling portion 156 of each piece 164, 166 may coupled to core 12 with bracket attachment portions 158 unobstructed and substantially vertically aligned between pieces 164 and 166 such that angle bracket 160 can couple to core 12 when core 12 is folded into a cornice/valance shape. Angle brackets 160 may be angled other than at 90-degrees to allow the cornice to be at, or appear to be at the desired angle. For example, angle bracket 160 may be angled at 80-85 degrees (e.g., 83 degrees). A variety of angle brackets 160 may be provided with system 10. Also, while angle bracket 160 has been illustrated with holes in each length, e.g., for screws, they are not necessary in all cases.

Mounting of cornice or valance system 10 and a related method will now be described with reference to the embodiments of FIGS. 1-7. It will be readily apparent that the teachings are equally applicable to the FIG. 8 embodiment. As shown in FIG. 9, assembly system 50 receives a mounting bracket 182 for attaching cornice or valance system 10 to a fixed support 190 (e.g., wall or window). Alternatively, mounting bracket 182 may engage a window treatment headrail, i.e., not the wall or window directly. FIGS. 10A-C show a variety of mounting brackets 82, 182, 282 that may be employed to mount the cornice or valance system 10 depending on its size and the structure of the window treatment. Each mounting bracket 82, 182, 282 may include an L-shaped bracket of a sufficiently rigid material to support system 10, e.g., metal, stiff plastic, etc. FIG. 10A shows an inside mount or shallow mount bracket, e.g., for end returns of about 1.5″, 2″ or 2.5″; FIG. 10B shows an outside mount bracket, e.g., for returns of about 3″; and FIG. 10C shows an outside, two-part mount bracket, e.g., for returns of about 4″ or greater. Brackets 82, 182, 282 may be inserted onto shorter coupling portion 80 (FIG. 7) of coupling portion 56 of assembly system 50 at two or more places along its length, with the longer part of the L orientation of the bracket directed away from the main core 12 surface and in the same direction as end return non-foldable regions 20. As shown in an employed state in FIG. 9, mounting brackets 82, 182, 282 may include snap fit slots 90 (near end thereof) for engaging portion 80. Other mechanisms for coupling to assembly system 50 may also be possible. Mounting brackets 82, 182, 282 can then be slipped into the space between window covering headrail and the window opening (not shown), or attached by other bracket means thereto, to mount cornice or valance system 10. Any additional structures now known or later developed for mounting cornices or valences may also be employed.

In an alternative embodiment of the invention, a method of creating cornice or valance system 10 for use with or over a window treatment may be provided as described herein including: forming a pair of foldable regions 16 near each end of single-piece core 12, as described herein. Foldable regions 16 define non-foldable regions including central region 18 and two end return non-foldable regions 20. As noted above, single-piece core 12 includes one of a pattern and a fabric 26 covering having a pattern. The method may further include coupling a first piece 64 of assembly system 50 to each end return non-foldable region 20 and coupling a second piece 66 of assembly system 50 to central region 18. Each piece 64, 66 includes a first, coupling portion 56 for coupling to single-piece core 12 and a slot portion 58. At least one angle bracket 60 is provided for later assembly. Angle bracket 60 engages adjacent slot portions 58, i.e., slots 40, of one of end return non-foldable regions 20 and central region 18 to retain a desired angle between central region 18 and the respective return region 20, thus creating cornice or valance system 10.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. The embodiment was chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated. 

What is claimed is:
 1. A cornice or valance system for use with or over a window treatment, the system comprising: a single-piece core with a foldable region near each end, the foldable regions defining a central non-foldable region and an end return non-foldable region at each end of the central non-foldable region; a slot, associated with the single-piece core, to each side of each foldable region; and an angle bracket for inserting into the slots to each side of a selected foldable region to retain a desired angle between the central non-foldable region and the respective end return non-foldable region.
 2. A cornice or valance system according to claim 1, wherein the desired angle is substantially 90 degrees.
 3. A cornice or valance system according to claim 1, wherein the single-piece core is comprised of a sheet material with outer skins and a less substantial inner structure.
 4. A cornice or valance system according to claim 3, wherein the sheet material includes a fluted polymer or a corrugated polymer.
 5. A cornice or valance system according to claim 1, wherein the core is covered with a fabric.
 6. A cornice or valance system according to claim 6, wherein a pattern of the fabric matches a pattern of an associated window covering material of the window treatment.
 7. A cornice or valance system according to claim 6, wherein the fabric is printed to order with a unique, buyer-specified pattern or color.
 8. A cornice or valance system according to claim 1, wherein the slot is provided by an assembly system attached to the single-piece core.
 9. A cornice or valance system according to claim 8, wherein the assembly system receives a mounting bracket for attaching the single-piece core to a fixed support.
 10. A cornice or valance system according to claim 9, wherein the mounting bracket engages a window treatment headrail.
 11. A cornice or valance system for use with or over a window treatment, the system comprising: a single-piece core with a pair of foldable regions near each end, the foldable regions defining a central region and two return regions; an assembly system having a first piece coupled to each return region and a second piece coupled to the central region, each piece including a first, coupling portion for coupling to the single-piece core and a slot portion; and an angle bracket for engaging adjacent slot portions of one of the return regions and the central region to retain a desired angle between the central region and the respective return region.
 12. A cornice or valance system according to claim 11, wherein the desired angle is substantially 90 degrees.
 13. A cornice or valance system according to claim 11, wherein the single-piece core is comprised of a sheet material with outer skins and a less substantial inner structure.
 14. A cornice or valance system according to claim 13, wherein the sheet material includes a fluted polymer or a corrugated polymer.
 15. A cornice or valance system according to claim 11, wherein the single-piece core is covered with a fabric.
 16. A cornice or valance system according to claim 14, wherein a pattern on the fabric matches a pattern of an associated window covering material of the window treatment.
 17. A cornice or valance system according to claim 14, wherein the fabric is printed to order with a unique, buyer-specified pattern or color.
 18. A cornice or valance system according to claim 11, wherein the first coupling portion receives a mounting bracket for attaching to a fixed support.
 19. A cornice or valance system according to claim 18, wherein the mounting bracket engages a window treatment headrail.
 20. A method of creating a cornice or valance system for use with or over a window treatment, the method comprising: forming a pair of foldable regions near each end of a single-piece core, the foldable regions defining a central region and two return regions, the single-piece core includes one of a pattern and a fabric covering having a pattern; coupling a first piece of an assembly system to each return region and coupling a second piece of an assembly system to the central region, each piece including a first, coupling portion for coupling to the single-piece core and a slot portion; and providing for later assembly at least one angle bracket for engaging adjacent slot portions of one of the return regions and the central region to retain a desired angle between the central region and the respective return region.
 21. A cornice or valance system for use with or over a window treatment, the system comprising: a single-piece core with a foldable region near each end, the foldable regions defining a central non-foldable region and an end return non-foldable region at each end of the central non-foldable region; and an angle bracket for coupling to each side of a selected foldable region to retain a desired angle between the central non-foldable region and the respective end return non-foldable region.
 22. A cornice of valance system according to claim 21, further comprising a slot, associated with the single-piece core, to each side of each foldable region, wherein the angle bracket is inserted into the slots to couple the angle bracket to each side of the selected foldable region.
 23. A cornice or valance system according to claim 22, wherein the slot is provided by an assembly system attached to the single-piece core.
 24. A cornice or valance system according to claim 23, wherein the assembly system receives a mounting bracket for attaching the single-piece core to a fixed support.
 25. A cornice or valance system according to claim 21, wherein the desired angle is substantially 90 degrees.
 26. A cornice or valance system according to claim 21, wherein the single piece core is comprised of a sheet material with outer skins and a less substantial inner structure.
 27. A cornice or valance system according to claim 26, wherein the sheet material includes a fluted polymer or a corrugated polymer.
 28. A cornice or valance system according to claim 21, wherein the single-piece core is covered with a fabric having a pattern that matches a pattern of an associated window covering material of the window treatment. 